Non-conforming golf balls

ABSTRACT

Golf balls having an initial velocity greater than 255 ft/sec and/or an overall distance of greater than 320 yards are disclosed. The golf balls comprise one or more core layers, one or more cover layers, and optionally one or more intermediate layers disposed between the core and the cover. At least one layer is optionally formed from a composition comprising from 2 wt % to 50 wt % of a plasticizer, based on the total weight of the composition.

FIELD OF THE INVENTION

The present invention relates to golf balls having an initial velocity and/or an overall distance that do not conform to the Initial Velocity rule and Overall Distance Standard established by the United States Golf Association.

BACKGROUND OF THE INVENTION

The Rules of Golf as approved by the United States Golf Association (“USGA”), include the following rules that relate to golf ball construction:

a. Weight

-   -   The weight of the ball shall not be greater than 1.620 ounces         avoirdupois (45.92 gm).

b. Size

-   -   The diameter of the ball shall be not less than 1.680 inches         (42.67 mm). This specification will be satisfied if, under its         own weight, a ball fails through a 1.680 inches diameter ring         gauge in fewer than 25 out of 100 randomly selected positions,         the test being carried out at a temperature of 23°+/−1° C.

c. Spherical Symmetry

-   -   The ball must not be designed, manufactured or intentionally         modified to have properties which differ from those of a         spherically symmetrical ball.

d. Initial Velocity

-   -   The velocity of the ball shall not be greater than 250 feet         (76.2 m) per second when measured on apparatus approved by the         United States Golf Association. A maximum tolerance of 2% will         be allowed. The temperature of the ball when tested will be         23°+/−1° C.

e. Overall Distance Standard

-   -   The overall distance shall not be greater than 317.0 yards when         tested on apparatus at the USGA Headquarters under the         conditions set forth in USGA-TPX3006 Revision 2.2.0 (Feb. 28,         2011). A maximum tolerance of 3.0 yards will be allowed.

The flight characteristics of a golf ball are determined by many factors, only three of which are typically controlled by the golfer when impacting the ball with a golf club: the speed of the golf ball, the launch angle, and the spin rate. The launch angle sets the initial trajectory of the golf ball's flight. The speed and spin of the ball give the ball lift, which will define the ball's overall flight path along with the weight, diameter, and drag of the golf ball. Where the ball stops after being struck by a golf club also depends greatly on the weather and the landing surface the ball contacts.

Many golfers have a low swing speed, meaning that the club head speed at impact is relatively slow when compared to that of a professional golfer. Typically, when driving a golf ball off of a tee, the average golf ball speed of a professional golfer is approximately 242 ft/sec (165 mph), The average golf ball speed of a low swing speed golfer is typically less than 176 ft/sec (120 mph). A golfer with a low swing speed has a corresponding low ball speed, resulting in a low overall distance.

Attempts have been made to improve golf ball distance for low swing speed golfers. For example, low weight golf balls have been manufactured, including Cayman Golf Company's Spectra® golf balls, the Ram Laser Light® golf balls, Titleist® DT® Carry golf balls, and the Pinnacle Equalizer® golf balls. When a club impacts a ball, conservation of momentum dictates that a lower weight ball will acquire greater initial velocity than a heavier ball. However, low weight golf balls slow down faster due to drag, an effect which is magnified at higher speeds. As a result, low weight golf balls can be beneficial for low swing speed players, but may not be good for high swing speed players.

Golf balls that exceed the USGA weight rule and/or have a diameter below the USGA minimum size requirement have also been taught for increasing distance. For example, U.S. Pat. No. 5,645,497 to Sullivan et al. discloses a golf ball wherein the core and cover have a combined weight of between 47 grams and 53 grams, a coefficient of restitution of at least substantially 0.800, and a Riehle compression between 0.037 inch and 0.045 inch, and the outside diameter of the ball is at least substantially 1.62 inches and less than 1.68 inches. Also,

U.S. Pat. No. 6,852,784 to Sullivan discloses non-conforming golf balls having an outside diameter of between about 1.62 inches and about 1.68 inches, wherein the core is comprised of a highly neutralized polymer.

There remains a need in the industry for golf balls having increased distance, particularly for low swing speed golfers. The present invention seeks to fulfill this need with golf balls having an initial velocity and/or an overall distance that do not conform to the Initial Velocity Rule and Overall Distance Standard established by the United States Golf Association.

SUMMARY OF THE INVENTION

The present invention is directed to a golf ball having an initial velocity greater than 255 ft/sec and/or an overall distance of greater than 320 yards. The golf ball comprises an inner core layer, an outer cover layer, and optionally an intermediate layer disposed between the inner core layer and the outer cover layer. In a particular embodiment, at least one of the layers is formed from a plasticized composition comprising from 2 wt % to 50 wt % of a plasticizer, based on the total weight of the plasticized composition. In a particular aspect of this embodiment, the inner core layer is formed from the plasticized composition. In another particular aspect of this embodiment, the outer cover layer is formed from the plasticized composition. In another particular aspect of this embodiment, the golf ball comprises an intermediate layer, and the intermediate layer is formed from the plasticized composition.

DETAILED DESCRIPTION OF THE INVENTION

Golf balls of the present invention do not conform to the Initial Velocity rule and/or the Overall Distance Standard (“ODS”) of the Rules of Golf as approved by the USGA. Under the Initial Velocity rule, the maximum allowable initial velocity is 250 ft/sec with a 2% tolerance (i.e., 255 ft/sec). Under the ODS, the maximum allowable overall distance in carry and roll is 317 yards with a maximum tolerance of 3 yards (i.e., 320 yards). Thus, golf balls of the present invention preferably have a non-conforming initial velocity of greater than 255 ft/sec, or greater than 256 ft/sec, or greater than 258 ft/sec, or greater than 260 ft/sec, and/or a non-conforming overall distance of greater than 320 yards, or greater than 325 yards, or 330 yards or greater, or greater than 330 yards, or 335 yards or greater, or greater than 335 yards, or 340 yards or greater, or greater than 340 yards, or 345 yards or greater, or greater than 345 yards, or 350 yards or greater, or greater than 350 yards, or 355 yards or greater, or 360 yards or greater.

The test method for measuring initial velocity for purposes of determining whether a golf ball conforms to the Initial Velocity rule is well known. The initial velocity test is conducted by conditioning a ball for a minimum of 3 hrs at 23°±1° C. The room in which the test is to be conducted is conditioned to 23°±2° C. The ball is then struck by a striking mass of approximately 250 lbs at a striker velocity of 143.8 ft/sec.

Initial velocity is related to the coefficient of restitution (“COR”) of the golf ball, Thus, the COR of the golf ball can be measured and correlated to initial velocity using known correlation methods in order to determine whether a golf ball conforms to the Initial Velocity rule, Such correlation methods are disclosed, for example, in U.S. Pat. No. 5,846,141 to Morgan et al., the entire disclosure of which is hereby incorporated herein by reference.

The test method for measuring the overall distance for purposes of determining whether a golf ball conforms to the ODS is well known. The overall distance test is conducted at the USGA Research and Test center as a two part test. Part one is conducted using the indoor Test Range (ITR), where the aerodynamic properties of the golf ball are characterized by the coefficient of lift (C_(L)) and the coefficient of drag (C_(D)). Part two is conducted using a mechanical golfer setup to achieve a calibrated launch condition for a reference golf ball (ball speed, spin rate and launch angle); the conditions determined in accordance with the USGA test procedure on file, section 5. The test golf balls, stored at a test temperature of 75° F.+/−1° F. (23.9° C.) for three hours, are then hit with the mechanical golfer to determine their specific launch conditions under the test setup conditions. The aerodynamic coefficients and the specific golf ball launch conditions are then combined to determine the overall distance (carry plus roll) for the specific golf ball under standard environmental conditions (75° F., 30 in Hg, and 50% relative humidity). Actual golf ball diameter, as determined by the USGA test procedure on file, and a weight of 1.620 ounces are used in the ODS determination.

In some embodiments, golf balls of the present invention additionally do not conform to the Weight rule and/or the Size rule of the Rules of Golf as approved by the USGA. Under the Weight rule, the maximum allowable weight of the golf ball is 1.620 ounces. Under the Size rule, the minimum allowable diameter of the golf ball is 1.680 inches. Thus, in one embodiment, golf balls of the present invention have a weight of greater than 1.620 ounces and/or a diameter of less than 1.680 inches. In a particular aspect of this embodiment, golf balls of the present invention have a weight of greater than 1.650 ounces, or greater than 1.700 ounces, or greater than 1.750 ounces, or greater than 1.800 ounces, or greater than 1.850 ounces, or greater than 1.900 ounces, or greater than 1.950 ounces, or 2.00 ounces or greater, or 2.20 ounces or greater. In another particular aspect of this embodiment, golf balls of the present invention have a diameter of less than 1.650 inches, or less than 1.630 inches, or 1.620 inches or less.

Golf balls of the present invention are multi-layer balls comprising one or more core layers and one or more cover layers. Each of the layers is formed from a composition independently selected from rubber compositions and thermoplastic compositions, including ionomeric and non-ionomeric compositions.

Suitable rubber compositions include a base rubber selected from natural and synthetic rubbers, including, but not limited to, polybutadiene, polyisoprene, ethylene propylene rubber (“EPR”), ethylene propylene diene rubber (“EPDM”), styrene butadiene rubber, styrenic block copolymer rubber, butyl rubber, halobutyl rubber, copolymers of isobutylene and para-alkylstyrene, halogenated copolymers of isobutylene and para-alkylstyrene, acrylonitrile butadiene rubber, polychloroprene, alkyl acrylate rubber, chlorinated isoprene rubber, acrylonitrile chlorinated isoprene rubber, polystyrene elastomers, polyethylene elastomers, polyurethane elastomers, polyurea elastomers, metallocene-catalyzed elastomers and plastomers, polyalkenamer, phenol formaldehyde, melamine formaldehyde, polyepoxide, polysiloxane, alkyd, polyisocyanurate, polycyanurate, polyacrylate, and combinations of two or more thereof. Diene rubbers are preferred, particularly polybutadiene, styrene butadiene, acrylonitrile butadiene, and mixtures of polybutadiene with other elastomers wherein the amount of polybutadiene present greater than 40 wt % based on the total polymeric weight of the mixture.

Non-limiting examples of suitable commercially available base rubbers are Buna CB high-cis neodymium-catalyzed polybutadiene rubbers, such as Buna CB 23, Buna CB24, and Buna CB high-cis cobalt-catalyzed polybutadiene rubbers, such as Buna CB 1203, 1220 and 1221, commercially available from Lanxess Corporation; SE BR-1220, commercially available from The Dow Chemical Company; Europrene® NEOCIS® BR 40 and BR 60, commercially available from Polimeri Europa®; UBEPOL-BR® rubbers, commercially available from UBE Industries, Inc.; BR 01, commercially available from Japan Synthetic Rubber Co., Ltd.; Neodene high-cis neodymium-catalyzed polybutadiene rubbers, such as Neodene BR 40, commercially available from Karbochem; TP-301 transpolyisoprene, commercially available from Kuraray Co., Ltd.; Vestenamer® polyoctenamer, commercially available from Evonik Industries; Butyl 065 and Butyl 288 butyl rubbers, commercially available from ExxonMobil Chemical Company; Butyl 301 and Butyl 101-3, commercially available from Lanxess Corporation; Bromobutyl 2224 and Chlorobutyl 1066 halobutyl rubbers, commercially available from ExxonMobil Chemical Company; Bromobutyl X2 and Chlorobutyl 1240 halobutyl rubbers, commercially available from Lanxess Corporation; BromoButyl 2255 butyl rubber, commercially available from Japan Synthetic Rubber Co., Ltd.; Vistalon® 404 and Vistalon® 706 ethylene propylene rubbers, commercially available from ExxonMobil Chemical Company; Dutral CO 058 ethylene propylene rubber, commercially available from Polimeri Europa; Nordel® IP NDR 5565 and Nordel® IP 3670 ethylene-propylene-diene rubbers, commercially available from The Dow Chemical Company; EPT1045 and EPT1045 ethylene-propylene-diene rubbers, commercially available from Mitsui Corporation; Buna SE 1721 TE styrene-butadiene rubbers, commercially available from Lanxess Corporation; Afpol 1500 and Afpol 552 styrene-butadiene rubbers, commercially available from Karbochem; Plioflex PLF 1502, commercially available from Goodyear Chemical; Nipol® DN407 and Nipol® 1041L acrylonitrile butadiene rubbers, commercially available from Zeon Chemicals, L.P.; Neoprene GRT and Neoprene AD30 polychloroprene rubbers; Vamac® ethylene acrylic elastomers, commercially available from E. I. du Pont de Nemours and Company; Hytemp® AR12 and AR214 alkyl acrylate rubbers, commercially available from Zeon Chemicals, L.P.; Hypalon® chlorosulfonated polyethylene rubbers, commercially available from E. I. du Pont de Nemours and Company; and Goodyear Budene® 1207 polybutadiene, commercially available from Goodyear Chemical. In a particular embodiment, the core is formed from a rubber composition comprising as the base rubber a blend of Neodene BR 40 polybutadiene, Budene® 1207 polybutadiene, and Buna SB 1502 styrene butadiene rubber. In another particular embodiment, the core is formed from a rubber composition comprising as the base rubber a blend of Neodene BR 40 polybutadiene, Buna CB 1221, and core regrind.

The rubber is crosslinked using, for example, a peroxide or sulfur cure system, C-C initiators, high energy radiation sources capable of generating free radicals, or a combination thereof. The rubber composition optionally includes one or more of the following: scorch retarder, antioxidant, soft and fast agent, filler, processing aid, processing oil, coloring agent, fluorescent agent, chemical blowing and foaming agent, defoaming agent, stabilizer, softening agent, impact modifier, free radical scavenger, and antiozonant (e.g., p-phenylenediames). Suitable types and amounts of rubber, initiator agent, coagent, filler, and additives are more fully described in, for example, U.S. Pat. Nos. 6,566,483, 6,695,718, 6,939,907, 7,041,721 and 7,138,460, the entire disclosures of which are hereby incorporated herein by reference. Particularly suitable diene rubber compositions are further disclosed, for example, in U.S. Patent Application Publication No. 2007/0093318, the entire disclosure of which is hereby incorporated herein by reference.

Suitable ionomer compositions include partially neutralized ionomers and highly neutralized ionomers, including ionomers formed from blends of two or more partially neutralized ionomers, blends of two or more highly neutralized ionomers, and blends of one or more partially neutralized ionomers with one or more highly neutralized ionomers. Preferred ionomers are salts of O/X- and O/X/Y-type acid copolymers, wherein O is an α-olefin, X is a C₃-C₈ α,β-ethylenically unsaturated carboxylic acid, and Y is a softening monomer. O is preferably selected from ethylene and propylene. X is preferably selected from methacrylic acid, acrylic acid, ethacrylic acid, crotonic acid, and itaconic acid. Methacrylic acid and acrylic acid are particularly preferred. As used herein, “(meth) acrylic acid” means methacrylic acid and/or acrylic acid. Likewise, “(meth) acrylate” means methacrylate and/or acrylate. Y is preferably selected from (meth) acrylate and alkyl (meth) acrylates wherein the alkyl groups have from 1 to 8 carbon atoms, including, but not limited to, n-butyl (meth) acrylate, isobutyl (meth) acrylate, methyl (meth) acrylate, and ethyl (meth) acrylate. Particularly preferred O/X/Y-type copolymers are ethylene/(meth) acrylic acid/n-butyl (meth) acrylate, ethylene/(meth) acrylic acid/isobutyl (meth) acrylate, ethylene/(meth) acrylic acid/methyl (meth) acrylate, and ethylene/(meth) acrylic acid/ethyl (meth) acrylate. The acid is typically present in the acid copolymer in an amount of 6 wt % or greater, or 9 wt % or greater, or 10 wt % or greater, or 11 wt % or greater, or 15 wt % or greater, or 16 wt % or greater, or 19 wt % or greater, or 20 wt % or greater, or in an amount within a range having a lower limit of 1 or 4 or 6 or 8 or 10 or 11 or 12 or 15 wt % and an upper limit of 15 or 16 or 17 or 19 or 20 or 20.5 or 21 or 25 or 30 or 35 or 40 wt %, based on the total weight of the acid copolymer. The acid copolymer is at least partially neutralized with a cation source, optionally in the presence of a high molecular weight organic acid, such as those disclosed in U.S. Pat. No. 6,756,436, the entire disclosure of which is hereby incorporated herein by reference. In a particular embodiment, less than 40% of the acid groups present in the composition are neutralized. In another particular embodiment, from 40% to 60% of the acid groups present in the composition are neutralized. In another particular embodiment, from 60% to 70% of the acid groups present in the composition are neutralized. In another particular embodiment, from 60% to 80% of the acid groups present in the composition are neutralized. In another particular embodiment, from 70% to 80% of the acid groups present in the composition are neutralized. In another embodiment, from 80% to 100% of the acid groups present in the composition are neutralized. Suitable cation sources include, but are not limited to, metal ion sources, such as compounds of alkali metals, alkaline earth metals, transition metals, and rare earth elements; ammonium salts and monoamine salts; and combinations thereof. Preferred cation sources are compounds of magnesium, sodium, potassium, cesium, calcium, barium, manganese, copper, zinc, tin, lithium, and rare earth metals. In a particular embodiment, the ionomer composition includes a bimodal ionomer, for example, DuPont® AD1043 ionomers, and the ionomers disclosed in U.S. Patent Application Publication No. 2004/0220343 and U.S. Patent Nos. 6,562,906, 6,762,246 and 7,273,903, the entire disclosures of which are hereby incorporated herein by reference. Suitable ionomers are further disclosed, for example, in U.S. Patent Application Publication Nos. 2005/0049367, 2005/0148725, 2005/0020741, 2004/0220343, and 2003/0130434, and U.S. Pat. Nos. 5,587,430, 5,691,418, 5,866,658, 6,100,321, 6,562,906, 6,653,382, 6,756,436, 6,777,472, 6,762,246, 6,815,480, 6,894,098, 6,919,393, 6,953,820, 6,994,638, 7,375,151, and 7,652,086, the entire disclosures of which are hereby incorporated herein by reference.

Suitable ionomer compositions also include blends of one or more partially- or fully-neutralized polymers with additional thermoplastic and thermoset materials, including, but not limited to, non-ionomeric acid copolymers, engineering thermoplastics, fatty acid/salt-based highly neutralized polymers, polybutadienes, polyurethanes, polyureas, polyesters, polyamides, polycarbonate/polyester blends, thermoplastic elastomers, maleic anhydride-grafted metallocene-catalyzed polymers (e.g., maleic anhydride-grafted metallocene-catalyzed polyethylene), and other conventional polymeric materials.

Suitable ionomeric compositions are further disclosed, for example, in U.S. Pat. Nos. 6,653,382, 6,756,436, 6,777,472, 6,894,098, 6,919,393, and 6,953,820, the entire disclosures of which are hereby incorporated herein by reference.

Also suitable are polyester ionomers, including, but not limited to, those disclosed, for example, in U.S. Pat. Nos. 6,476,157 and 7,074,465, the entire disclosures of which are hereby incorporated herein by reference.

Also suitable are thermoplastic elastomers comprising a silicone ionomer, as disclosed, for example, in U.S. Pat. No. 8,329,156, the entire disclosure of which is hereby incorporated herein by reference.

Also suitable are the following non-ionomeric polymers, including homopolymers and copolymers thereof, as well as their derivatives that are compatibilized with at least one grafted or copolymerized functional group, such as maleic anhydride, amine, epoxy, isocyanate, hydroxyl, sulfonate, phosphonate, and the like:

-   -   (a) polyesters, particularly those modified with a         compatibilizing group such as sulfonate or phosphonate,         including modified poly(ethylene terephthalate), modified         poly(butylene terephthalate), modified poly(propylene         terephthalate), modified poly(trimethylene terephthalate),         modified poly(ethylene naphthenate), and those disclosed in U.S.         Pat. Nos. 6,353,050, 6,274,298, and 6,001,930, the entire         disclosures of which are hereby incorporated herein by         reference, and blends of two or more thereof;     -   (b) polyamides, polyamide-ethers, and polyamide-esters, and         those disclosed in U.S. Pat. Nos. 6,187,864, 6,001,930, and         5,981,654, the entire disclosures of which are hereby         incorporated herein by reference, and blends of two or more         thereof;     -   (c) polyurethanes, polyureas, polyurethane-polyurea hybrids, and         blends of two or more thereof;     -   (d) fluoropolymers, such as those disclosed in U.S. Pat. Nos.         5,691,066, 6,747,110 and 7,009,002, the entire disclosures of         which are hereby incorporated herein by reference, and blends of         two or more thereof;     -   (e) non-ionomeric acid polymers, such as E/X- and E/X/Y-type         copolymers, wherein E is an olefin (e.g., ethylene), X is a         carboxylic acid such as acrylic, methacrylic, crotonic, maleic,         fumaric, or itaconic acid, and Y is an optional softening         comonomer such as vinyl esters of aliphatic carboxylic acids         wherein the acid has from 2 to 10 carbons, alkyl ethers wherein         the alkyl group has from 1 to 10 carbons, and alkyl         alkylacrylates such as alkyl methacrylates wherein the alkyl         group has from 1 to 10 carbons; and blends of two or more         thereof;     -   (f) metallocene-catalyzed polymers, such as those disclosed in         U.S. Pat. Nos. 6,274,669, 5,919,862, 5,981,654, and 5,703,166,         the entire disclosures of which are hereby incorporated herein         by reference, and blends of two or more thereof;     -   (g) polystyrenes, such as poly(styrene-co-maleic anhydride),         acrylonitrile-butadiene-styrene, poly(styrene sulfonate),         polyethylene styrene, and blends of two or more thereof;     -   (h) polypropylenes and polyethylenes, particularly grafted         polypropylene and grafted polyethylenes that are modified with a         functional group, such as maleic anhydride of sulfonate, and         blends of two or more thereof;     -   (i) polyvinyl chlorides and grafted polyvinyl chlorides, and         blends of two or more thereof;     -   (j) polyvinyl acetates, preferably having less than about 9% of         vinyl acetate by weight, and blends of two or more thereof;     -   (k) polycarbonates, blends of         polycarbonate/acrylonitrile-butadiene-styrene, blends of         polycarbonate/polyurethane, blends of polycarbonate/polyester,         and blends of two or more thereof;     -   (l) polyvinyl alcohols, and blends of two or more thereof;     -   (m) polyethers, such as polyarylene ethers, polyphenylene         oxides, block copolymers of alkenyl aromatics with vinyl         aromatics and poly(amic ester)s, and blends of two or more         thereof;     -   (n) polyimides, polyetherketones, polyamideimides, and blends of         two or more thereof;     -   (o) polycarbonate/polyester copolymers and blends; and     -   (p) combinations of any two or more of the above thermoplastic         polymers.

Examples of commercially available thermoplastics suitable for forming thermoplastic layers include, but are not limited to, Pebax® thermoplastic polyether block amides, commercially available from Arkema Inc.; Surlyn® ionomer resins, Hytrel® thermoplastic polyester elastomers, and ionomeric materials sold under the trade names DuPont® HPF 1000, HPF 2000, HPF AD 1035, HPF AD 1040, all of which are commercially available from E. I. du Pont de Nemours and Company; lotek® ionomers, commercially available from ExxonMobil Chemical Company; Amplify® IO ionomers of ethylene acrylic acid copolymers, commercially available from The Dow Chemical Company; Clarix® ionomer resins, commercially available from A. Schulman Inc.; Elastollan® polyurethane-based thermoplastic elastomers, commercially available from BASF; and Xylex® polycarbonate/polyester blends, commercially available from SABIC Innovative Plastics. Non-conforming initial velocity and overall distance properties of the golf balls of the present invention are preferably achieved solely or in part by one or more of the following: forming one or more of the golf ball layers from a plasticized polymer composition, forming one or more of the golf ball layers from a composition comprising filler in an amount sufficient to increase the weight of the golf ball to greater than 1.620 ounces, constructing the golf ball to an overall diameter of less than 1.680 inches, and providing the golf ball with a particular dimple design. In embodiments wherein the golf ball has at least one layer formed from a plasticized polymer composition and at least one layer formed from a filled composition, the filled layer can be the same layer as or a different layer than the layer formed from the plasticized polymer composition.

In one embodiment, forming one or more of the golf ball layers from a plasticized polymer composition contributes to the non-conforming initial velocity and overall distance properties of the golf balls of the present invention. In a particular aspect of this embodiment, the present invention is directed a golf ball comprising an inner core layer and an outer cover layer, wherein the inner core layer is formed from a plasticized polymer composition. In another particular aspect of this embodiment, the present invention is directed to a golf ball comprising an inner core layer and an outer cover layer, wherein the outer cover layer is formed from a plasticized polymer composition. In another particular aspect of this embodiment, the present invention is directed to a golf ball comprising an inner core layer, an outer cover layer, and an intermediate layer disposed between the inner core layer and the outer cover layer, wherein the intermediate layer is formed from a plasticized polymer composition.

Suitable plasticized polymer compositions include a plasticizer in an amount sufficient to substantially change the stiffness and/or hardness of the composition, and typically comprise from 20 to 99.5 wt % of the polymer and from 0.5 to 80 wt % of the plasticizer, based on the combined weight of the polymer and the plasticizer. In a particular embodiment, the plasticizer is present in an amount of 0.5% or 1% or 3% or 5% or 7% or 8% or 9% or 10% or 12% or 15% or 18% or 20% or 22% or 25% or 30% or 35% or 40% or 42% or 50% or 55% or 60% or 66% or 71% or 75% or 80%, by weight based on the combined weight of the polymer and the plasticizer, or the plasticizer is present in an amount within a range having a lower limit and an upper limit selected from these values. Suitable polymers include acid copolymers, partially neutralized acid copolymers, highly neutralized acid polymers (“HNPs”), polyesters, polyamides, thermosetting and thermoplastic polyurethanes.

Suitable plasticized acid copolymer compositions, plasticized partially neutralized acid copolymer compositions, and plasticized HNP compositions, and particularly suitable golf ball constructions utilizing such compositions, are further disclosed, for example, in U.S. patent application Ser. No. 14/460,416, U.S. patent application Ser. No. 14/490,976, U.S. patent application Ser. No. 14/576,800, and U.S. patent application Ser. No. 14/588,317, the entire disclosures of which are hereby incorporated herein by reference.

Suitable plasticized polyester compositions, and particularly suitable golf ball constructions utilizing such compositions, are further disclosed, for example, in U.S. patent application Ser. No. 14/532,141, the entire disclosure of which is hereby incorporated herein by reference.

Suitable plasticized polyamide compositions, and particularly suitable golf ball constructions utilizing such compositions, are further disclosed, for example, in U.S. patent application Ser. No. 14/309,066, U.S. patent application Ser. No. 14/330,189, U.S. patent application Ser. No. 14/527,835, and U.S. patent application Ser. No. 14/576,324, the entire disclosures of which are hereby incorporated herein by reference.

Suitable plasticized polyurethane compositions, and particularly suitable golf ball constructions utilizing such compositions, are further disclosed, for example, in U.S. patent application Ser. No. 14/672,538, U.S. patent application Ser. No. 14/672,523, U.S. patent application Ser. No. 14/672,485, and U.S. patent application Ser. No. 14/691,720, the entire disclosures of which are hereby incorporated herein by reference.

In another embodiment, forming one or more of the golf ball layers from an HNP composition, wherein the HNP composition is formed by blending an acid polymer, a non-acid polymer, a cation source, and a fatty acid or metal salt thereof, contributes to the non-conforming initial velocity and overall distance properties of the golf balls of the present invention. Such HNP compositions, and particularly suitable golf ball constructions utilizing such compositions, are further disclosed, for example, in U.S. Patent Application Publication No. 2014/0113748, the entire disclosure of which is hereby incorporated herein by reference. In a particular aspect of this embodiment, the present invention is directed a golf ball comprising an inner core layer and an outer cover layer, wherein the inner core layer is formed from the HNP composition. In another particular aspect of this embodiment, the present invention is directed to a golf ball comprising an inner core layer and an outer cover layer, wherein the outer cover layer is formed from the HNP composition. In another particular aspect of this embodiment, the present invention is directed to a golf ball comprising an inner core layer, an outer cover layer, and an intermediate layer disposed between the inner core layer and the outer cover layer, wherein the intermediate layer is formed from the HNP composition.

In another embodiment, forming one or more of the golf ball layers from a filled composition contributes to the non-conforming initial velocity and overall distance properties of the golf balls of the present invention. The filled composition comprises filler in an amount sufficient to increase the weight of the golf ball to greater than 1.620 ounces, or greater than 1.650 ounces, or greater than 1.700 ounces, or greater than 1.750 ounces, or greater than 1.800 ounces, or greater than 1.850 ounces, or greater than 1.900 ounces, or greater than 1.950 ounces, or 2.00 ounces or greater, or 2.20 ounces or greater. Any suitable filler, flake, fiber, particle, or the like, of an organic or inorganic material may be used, as further disclosed in U.S. Pat. Nos. 6,494,795, 6,547,677, 6,743,123, 7,074,137, and 6,688,991, and U.S. Patent Application Publication No. 2014/0113749, the entire disclosures of which are hereby incorporated herein by reference

In another embodiment, constructing the golf ball to an overall diameter of less than 1.680 inches contributes to the non-conforming initial velocity and overall distance properties of the golf balls of the present invention. In a particular aspect of this embodiment, the present invention is directed to a golf ball having an outside diameter of less than 1.650 inches, or less than 1.630 inches, or 1.620 inches or less

In another embodiment, providing the golf ball with a particular dimple design contributes to the non-conforming overall distance properties of the golf balls of the present invention. The golf balls preferably have a dimple coverage of 65% or greater, or 70% or greater, or 75% or greater, or 80% or greater, or 85% or greater, or 90% or greater, or 95% or greater. The dimples generally have a plan view shape selected from circular, polygonal, oval, flower-like lobed, multi-armed, amorphous, and annular; and a cross-sectional profile shape selected from spherical, truncated, catenary, multi-radius, saucer, dimple-in-dimple, conical, and bramble. The dimples are typically arranged in an overall pattern selected from polyhedron-based patterns, phyllotaxis-based patterns, spherical tiling patterns, and random arrangements. The dimples preferably have an edge angle of 10.0° or 11.0° or 11.5° or 12.0° or 12.5° or 13.0° or 13.5° or 14.0°, or an edge angle having a lower limit and an upper limit selected from these values.

In a particular embodiment, the present invention provides a golf ball having an outer diameter of 1.680 inches or greater, a weight of 1.620 ounces or less, and an overall distance of greater than 320, wherein the outer surface of the golf ball comprises a plurality of dimples, the majority of which have an edge angle of 13.0° or 13.5 or 14.0°, or an edge angle of 13.5°.

In another particular embodiment, the present invention provides a golf ball having an outer diameter of 1.680 inches or greater, a weight of greater than 1.620 ounces, and an overall distance of 330 yards or greater, wherein the outer surface of the golf ball comprises a plurality of dimples, the majority of which have an edge angle of 12.0° or 12.5° or 13.0° or 13.5°, or an edge angle within a range having a lower limit and an upper limit selected from these values. In a particular aspect of this embodiment, the weight of the golf ball is 1.80 ounces or greater, or 2.00 ounces or greater, or 2.20 ounces or greater. In another particular aspect of this embodiment, the golf ball has an overall distance of 335 yards or greater, or 340 yards or greater, or 345 yards or greater, or 350 yards or greater.

In another particular embodiment, the present invention provides a golf ball having an outer diameter of less than 1.680 inches, a weight of greater than 1.620 ounces, and an overall distance of 350 yards or greater, wherein the outer surface of the golf ball comprises a plurality of dimples, the majority of which have an edge angle of 11.5° or 12.0° or 12.5°, or an edge angle within a range having a lower limit and an upper limit selected from these values. In a particular aspect of this embodiment, the weight of the golf ball is 1.80 ounces or greater, or 2.00 ounces or greater, or 2.20 ounces or greater. In another particular aspect of this embodiment, the golf ball has an overall distance of 355 yards or greater, or 360 yards or greater.

When numerical lower limits and numerical upper limits are set forth herein, it is contemplated that any combination of these values may be used.

All patents, publications, test procedures, and other references cited herein, including priority documents, are fully incorporated by reference to the extent such disclosure is not inconsistent with this invention and for all jurisdictions in which such incorporation is permitted.

While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those of ordinary skill in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and descriptions set forth herein, but rather that the claims be construed as encompassing all of the features of patentable novelty which reside in the present invention, including all features which would be treated as equivalents thereof by those of ordinary skill in the art to which the invention pertains. 

What is claimed is:
 1. A golf ball comprising at least one layer formed from a plasticized composition comprising from 2 wt % to 50 wt %, based on the total weight of the plasticized composition, of a plasticizer, wherein the golf ball has an overall distance of greater than 320 yards.
 2. The golf ball of claim 1, wherein the golf ball has an initial velocity of greater than 255 ft/sec.
 3. The golf ball of claim 1, wherein the overall distance is 330 yards or greater.
 4. The golf ball of claim 1, wherein the overall distance is 340 yards or greater.
 5. The golf ball of claim 1, wherein the overall distance is 350 yards or greater.
 6. The golf ball of claim 1, wherein the golf ball comprises a plurality of dimples on the outer surface thereof, and wherein greater than 50% of the dimples have an edge angle of from 13.0° to 14.0°.
 7. The golf ball of claim 1, wherein the golf ball has a weight of greater than 1.620 ounces.
 8. The golf ball of claim 7, wherein the golf ball comprises a plurality of dimples on the outer surface thereof, and wherein greater than 50% of the dimples have an edge angle of from 11.5° to 13.5°.
 9. The golf ball of claim 8, wherein the overall distance is 335 yards or greater.
 10. The golf ball of claim 1, wherein the golf ball has an outer diameter of less than 1.680 inches.
 11. The golf ball of claim 1, wherein the golf ball has an outer diameter of less than 1.650 inches.
 12. The golf ball of claim 11, wherein the golf ball has a weight of greater than 1.620 ounces.
 13. The golf ball of claim 12, wherein the golf ball comprises a plurality of dimples on the outer surface thereof, and wherein greater than 50% of the dimples have an edge angle of from 11.5° to 13.5°.
 14. The golf ball of claim 13, wherein the overall distance is 350 yards or greater.
 15. The golf ball of claim 14, wherein the overall distance is 355 yards or greater.
 16. The golf ball of claim 1, wherein the golf ball comprises an inner core layer and an outer cover layer, and wherein the inner core layer is formed from the plasticized composition.
 17. The golf ball of claim 1, wherein the golf ball comprises an inner core layer and an outer cover layer, and wherein the outer cover layer is formed from the plasticized composition.
 18. The golf ball of claim 1, wherein the golf ball comprises an inner core layer, an outer cover layer, and an intermediate layer disposed between the inner core layer and the outer cover layer, wherein the intermediate layer is formed from the plasticized composition. 